Clapper type relay having solderless electrical connections



Patented Mar. 8, 1966 3,239,630 CLAPPER TYPE RELAY HAVING SOLDERLESS ELECTRICAL CONNECTIONS Thedore .I. Obszarny, Chicago, John J. Rowcll, Glenview, John Schmidt, Mount Prospect, and William Warren Wright, Wheaton, Ill., 'assiguors to Guardian Electric Manufacturing Co., a corporation of Illinois Filed Apr. 30, 1964, Ser. No. 363,822 6 Claims. (Cl. 200104) This invention relates to improved clapper type relays and it particularly relates to clapper type relays wherein soldered electrical connections are substantially avoided.

The electrical equipment industry is known to be highly competitive and in such an industry, it is very desirable to provide products which are highly economical to manufacture while maintaining and preferably enhancing the quality of the products. This competition is particularly keen in the manufacture of relays, such as clapper type relays.

Although great advances have been. made in providing highly economical and eflicient relays, a remaining source of undesirable expense is in the provision of numerous solder connections. For example, in connecting a switch blade contact member of a relay to an external circuit, the end of the blade contact member, which is fixed in a mounting block, is ordinarily soldered to the end of a wire which, in turn, is soldered to a terminal or to a piece of electrical equipment. Thus, two solder connections are commonly required for connecting a single switch blade member with an external circuit. Also, it is common practice to provide multiple switch blades for controlling a multiplicity of circuits by operation of a single relay coil and armature; as a result,-the cost of soldered connections is increased accordingly.

Solder connections are not only expensive, but they also require relatively high degree of skill in providing proper connections. Consequently, an undesirably large number of improper solder connections result and such improper connections adversely affect the operation of the relay. Another disadvantage of solder connection is that they have a relatively large voltage drop. Still further, soldered electrical connections require the use of flux, which, if improperly used, may damage wire insulation or other component parts of the relay.

It is therefore an important object of this invention to substantially avoid the disadvantages of solder connections commonly used in prior relay constructions.

It is a further object of this invention to provide an improved clapper type relay which is characterized by its simplicity and economy of construction and manufacture.

It is another object of this invention to provide an improved clapper type relay wherein moving blade contact members serve a dual function in operating electrical circuits in response to the energization and de-energization of an electrical coil and in providing integral means for electrically connecting the blade contact members to the terminals wherein the use of soldered connections for moving blade contact members is avoided.

It is yet another object of this invention to provide an improved electrical clapper type relay wherein, by substantially avoiding the use of solder connections,'the cost of manufacture is decreased and the reliability of operation of the relay is increased.

One type of relay wherein soldered connections are commonly used is the plug-in type. In such relays, a wire is ordinarily soldered to the connector end of the moving blade contact member while the other end of the wire is soldered to an appropriate plug which is adapted to be inserted into the base of a plug-in connection. In these relays, a plurality of plugs are supported on a base; thus, a subassembly, including a plurality of plugs and an insulated base, is required. These subassemblies are undesirable since they are both expensive and require soldered connections. Therefore, it is another object of this invention to avoid the use of the sub-assembly commonly required for plug-in relays.

Further purposes and objects of this invention will appear as the specification proceeds.

A particular embodiment of the present invention is illustrated in the accompanying drawings wherein:

FIGURE 1 is a side elevational view of one embodiment of our improved clapper type relay;

FIGURE 2 is an end elevational view of the embodiment of FIGURE 1, except that the base for receiving the relay construction is not shown;

FIGURE 3 is a top plan view of the base, shown in FIGURE 1, for receiving our relay construction;

FIGURE 4 is an enlarged, fragmentary top plan view of terminal members mounted in the base of our relay construction;

FIGURE 5 is a sectional view taken along the line 55 of FIGURE 4; and

FIGURE 6 is an exploded, perspective view of the armature, insulator, and moving blade contact sub-assembly used in our relay construction.

Referring particularly to FIGURES 1 and 2, our relay construction 10 is provided with a base 12 of insulating material, upon which a field piece 14 is rigidly mounted. The field piece 14 of magnetic material includes an upstanding leg 16 and a forwardly projecting arm 18, which is substantially parallel to the upper surface of the base 12. A core 20 of magnetic material is mounted centrally of the upstanding planar leg 16 and is positioned intermediate and substantially parallel to the upper surface of the .base 12 and the arm 18. The core 20 has mounted thereon a bobbin 22 of insulating material upon which an electrical coil member 24 is securely positioned. The bobbin 22 and coil 24 are secured in place on the field piece 14 by means of a securing ring 26, which cooperates with the split end of the core 20. Leads, as 28, extend from opposite ends of the coil 24 and are connected, as by welding to a pair of upstanding terminals, as 30, which are mounted in and pass through the base 12. As will be shown hereinafter, the welded electrical connections between the terminals 30 and the coil leads 28 are the only soldered or welded connections used in our relay construction.

An armature 32 of magnetic material is pivotably carried at the outer or forward end 34 of the planar arm 18 of the field piece 14. Recesses 36 are located on opposite sides of the pivot edge 38 of the armature 32 and cooperate with suitable recesses (not shown) provided in the forward end 34 of the field piece 14. A small strip 40 of non-magnetic material, such as copper, is positioned intermediate the pivot edge of the field piece 14 and the pivot edge 38 of the armature 32 so as to break the magnetic field between the armature 32 and the field piece 14. The rear portion of the forwardly projecting arm 18 of the field piece 14 is provided with an upstanding projection 42 and the armature 32 is provided with an upstanding tongue at its pivoted end. The tongue 44 is in substantial alignment with the projection 42 and a tension spring 46 is secured at one end to the projection 42 and at the other end to the tongue 44. The spring 46 normally biases the armature 32 away from the electrical coil 24, or, as viewed in FIGURE 1, in a counterclockwise direction.

Referring more particularly to FIGURE 6, a plurality of switch blade members 48 are carried by a molded mounting block 50 of insulating material. The switch blades 48 are mounted in the block 50 by means of molding. The mounting block 50 may be constructed of any suitable moldable, electrical insulating material and the switch blades 48 may be constructed of any suitable electrically conductive, springable material.

The moving switch blades 48 are spaced from each other in the mounting block 50 so as to be electrically insulated from each other. Fingers 52 project from opposite sides of the elongated mounted blocks 50 and are positioned intermediate the switch blades 48, thereby assuring electrical insulation therebetween. The central, outer portion of the mounting block 50 is raised and includes a depressed central portion 54 therein. A pair of spaced apertures 56 are positioned therein, intermediate adjacent switch blades 48. The switch blades 48 are not to project into the apertures 56 so as to maintain the apertures 56 electrically insulated from the blades 48. Screws 58 are passed through the apertures 56 and are threaded into the threaded openings 60 positioned on the armature 3-2 for rigidly securing the mounting block 50 to the armature 32.

An important feature of our improved relay construction is the provision of looped or U-shaped blade members 48 for substantially avoiding the use of soldered electrical connections in the relay 10. The free or moving end 62 of the blades 48 are provided with contact buttons or rivets 64 which may be positioned on one or both sides thereof. The buttons or rivets 64 are in alignment with opposed electrical contact members 66 and 68, which are rigidly mounted in the base 12. As shown best in FIGURE 1, the outermost of the contact buttons 64 are normally maintained in contact with the upper or contact end of the electrical contact member 66 while the coil 24 is de-energized. Upon energization of the coil 24, the armature 32 is pivoted towards the coil 24 and the other or inner set of contact buttons 64 move into electrical contact with the contact ends of the electrical contact members 68. Upon de-energization of the coil 24, the armature 32 moves away from the coil 24, thereby moving the blades 48 and the outer set of contact rivets 64 back into electrical contact with the outer set of contact members 66. In the mounting of the contact members 66 and 68 in the base 12, the spacing therebetween is to be great enough so that only one set of the contact members 66 or 68 is to be in contact with the rivets 64, while the spacing is to be close enough so that the contact rivets 64 are in good electrical contact with the contact members 66 or 68.

In molding the switch blade members 48 in the mounting block 50, they initially extend directly outwardly from the mounting block 50. At the time of assembling the relay 10, the blade members 48 are formed in the manner shown in the drawings. More specifically, the :blade members 48 are formed to provide a first leg 70, which is mounted in the mounting block 50, a second leg 72, which is substantially parallel to and outward of the first leg 70, and the first and second legs 78 and '72 are joined by a looped or bight portion 74. In forming the bight portion 74, care must be taken to assure that the operation of the spring 46 and armature 32 is relatively unaffected by any biasing action at the bight portions 74 of the switch blade members. Also, as the connector ends 76 of the switch blades 48 are inserted on the terminal members 78, care is taken, again to assure that the desired operation of the relay 38 is relatively unaffected by the looped switch blade members 48.

The connector ends 76 of the blade members 48 are provided with inwardly turned ears 80 for providing a firm electrical connection with the upwardly projecting portions 82 of the terminal members 78. Also, it is highly desirable that the bi ght or looped portions 74 and portions of the second legs 72 be bifurcated so as to decrease the biasing action of the blade members 48 and the corresponding effect on the operation of the armature 32; also, the bifurcation provides for an increased cooling effect. The moving blade members 48 thus provide a dual function of making and breaking contact with the contact members 66 and 68 and of providing integral electrical connection with the terminal members 78, thereby avoiding the use of soldered connection for the moving blade contacts 48.

Referring to FIGURE 6, a molded insulating member 84 is mounted intermediate the mounting block 50 and the armature 32 so as to assure that electrical insulation is maintained between the forward end of the field piece 14 and the looped or bi'ght portions 74 of the blade members 48. The insulating member 84 is provided with a planar portion 86 which includes a pair of apertures 88 through which the screws 58 are passed for mounting the mounting block 50 and the insulating member 84 to the armature 32. An upwardly and forwardly angled portion 90 extends from the planar portion 86 and is interposed intermediate the switch blade members 48 and the outer end of the field piece 14.

Referring particularly to FIGURES 4 and 5, the details of the mounting of the terminals 78 in the base 12 are shown. The terminals 78 include thickened intermediate portions 92 having projections 94 extending substantially at right angles therefrom. The projections or shoulders 94 are adapted to abut the upper surface of the base 12 to thereby substantially prevent downward movement of the terminals '78 in the apertures 96 of the base 12. The terminals 78 are inserted through the apertures 96, which snugly receive the thickened portions 92 of the terminals 78. After inserting the terminals therethrough, the stops or shoulders 94 abut the upper surface of the base 12 and the lower ends of the intermediate portions 92 are staked outwardly to provide ears 98 which prevent upward movement of the terminals 78 in the base 12. The terminals 30 for the coil ends 28 are mounted in the base 12 in a similar manner. As to the contact members 66 and 68, the contact or upper portions are offset from the main body thereof, to thereby provide ledges 100 for abutting the upper surface of the base 12. The ledges 100 thus prevent downward movement. Ears 98 are provided on the contact members 66 and 68, as with the terminals 78, in order to prevent upward movement thereof within the base 12. Also, spaced ribs 101 are formed in the molded base 12 and pass lengthwise thereof so as to assure the maintenance of electrical insulation between adjacent terminal members 78 and adjacent contact members 66 and 68.

It is to be understood that the terminals 30, 66, 68, and 92 may be slightly deformed, as by ribbing or beading, in the area of contact with the base 12 so as to assure a snug tight fit of the terminals therein.

The downwardly projecting portions of the terminals 30, the contact members 66 and 68, and the terminal members 78 are constructed of a suitable rigid electrical conducting material, so that they may be inserted or plugged into the female portion of a connection. Referring to FIGURES 1 and 2, a base 102 is provided with a plurality of openings 104, having means for electrically engaging the downwardly projecting terminals 30, electrical connectors 66 and 68, and terminal members 78. Thus, in our construction, a sub-assembly commonly required for plug-in type relays, is unnecessary since the connectors or terminals 30, 66, 68, and 78, which are mounted in the base 12, cooperate with the electrical conducting means in the openings 104 provided in the base 102. Suitable connections are made to electrical circuits from the underside of the base 102 in a conventional manner.

While in the foregoing there has been provided a detailed description of a particular embodiment of the present invention, it is to be understood that all equivalents obvious to those having skill in the art are to be included within the scope of the invention, as claimed.

What we claim and desire to secure by Letters Patent 1. For use with a clapper relay comprising a base, a field piece mounted on the base, a coil mounted on the field piece, and an armature mounted on the field piece and being pivotable thereon in response to energization and de-energization of the coil, the improvement comprising a contact member mounted on said base, a terminal member mounted on said base, and a moving blade member mounted on said armature and having a first leg, a second leg, and a connecting portion between said legs, said first leg having a contact rivet at its free end for moving in and out of electrical contact with said contact member in response to the pivoting of said armature and said second leg having an integral connector portion defined thereon for firmly electrically connecting said terminal member with said blade member.

2. The device of claim 1 wherein said connector portion and portions of said first leg and of said second leg are bifurcated whereby the pivoting of said armature is substantially unaffected by the biasing action of said moving blade member.

3. The device of claim 1 wherein a pair of opposed contact members are rigidly mounted in said base, said terminal member is rigidly mounted in said base and is in substantial alignment with said pair of opposed contact members, and a pair of contact rivets are carried on opposite sides of said free end of said moving blade member for making and breaking electrical contact with said contact members in response to the pivoting of said armature.

4. The device of claim 1 wherein a mounting block of insulating material is rigidly mounted on said armature, a plurality of aligned moving blade members are embedded in said mounting block, and an insulator member is mounted on said armature intermediate said armature and said mounting block for assuring electrical insulation between said field piece and said blade member and also between said armature and said blade member.

5. For use with a relay comprising a base, a field piece mounted on the base, a coil mounted on the field piece, and an armature mounted on the field piece and being pivotable thereon in response to energization and deenergization of said coil, the improvement comprising a pair of opposed contact members rigidly mounted on said base and passing therethrough, a terminal member rigidly mounted on said base and passing therethrough and being in substantial alignment with said contact members, a mounting block of insulating material being carried by said armature, and a moving blade member embedded in said mounting block for electrically insulating said blade member from said armature, said moving blade member having a first leg, a second leg, and a portion connecting said legs, said first leg having contact elements positioned on opposite sides of its moving end, said contact elements being adapted to move alternately in and out of electrical contact with said contact members in response to pivotable movement of said armature, said second leg having an integral connector element formed thereon for electrically connecting said blade member with said terminal member, whereby electrical current flows from either of said contact members to said terminal member by flowing through said blade member.

6. The improvement of claim 5 wherein a plurality of said pairs of contact members, a plurality of said terminal members, and a plurality of said moving blade members are provided.

References Cited by the Examiner UNITED STATES PATENTS 2,282,066 5/1942 Lake et al.

BERNARD A. GILHEANY, Primary Examiner.

R. N. ENVALL, JR., Assistant Examiner. 

1. FOR USE WITH A CLAPPER RELAY COMPRISING A BASE, A FIELD PIECE MOUNTED ON THE BASE, A COIL MOUNTED ON THE FIELD PIECE, AND AN ARMATURE MOUNTED ON THE FIELD PIECE AND BEING PIVOTABLE THEREON IN RESPONSE TO ENERGIZATION AND DE-ENERGIZATION OF THE COIL, THE IMPROVEMENT COMPRISING A CONTACT MEMBER MOUNTED ON SAID BASE, A TERMINAL MEMBER MOUNTED ON SAID BASE, AND A MOVING BLADE MEMBER MOUNTED ON SAID ARMATURE AND HAVING A FIRST LEG, A SECOND LEG, AND A CONNECTING PORTION BETWEEN SAID LEGS, SAID FIRST LEG HAVING A CONTACT RIVET AT ITS FREE END FOR MOVING IN AND OUT OF ELECTRICAL CONTACT WITH SAID CONTACT MEMBER IN RESPONSE TO THE PIVOTING OF SAID ARMATURE AND SAID SECOND LEG HAVING AN INTEGRAL CONNECTOR PORTION DEFINED THEREON FOR FIRMLY ELECTRICALLY CONNECTING SAID TERMINAL MEMBER WITH SAID BLADE MEMBER. 